FlowMaster II rotary driven hydraulic pump, series “A”he FlowMaster II rotary driven hydraulic...

FlowMaster II rotary driven hydraulic pump, series “A”85769, 120 lbs.85847, 40 lbs.

Operation, assembly, disassembly and troubleshooting guide

Date of issue January 2014

Form number 404534C

Section C8

Page 375B

Read manual prior to installation or use

of this product. Keep manual nearby for

future reference. Failure to follow

instructions and safety precautions may

result in death or serious injury.

DANGER

ContentsSafety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Explanation of signal words for safety . . . . . . . . . . . . . . . . . . . . . 3

Use of this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Appropriate use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

General description and information . . . . . . . . . . . . . . . . . . . . . 4

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Damaged pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Installing the Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Lincoln industrial standard warranty . . . . . . . . . . . . . . . . . . . 22

Special limited warranties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2

Explanation of signal words for safety

Safety

Read and carefully observe these installation

instructions before installing/operating/

troubleshooting the assembly. The assembly

must be installed, maintained and repaired

exclusively by persons familiar with the

instructions.

Install the assembly only after safety

instructions and this guide have been read

and are completely understood.

Adequate personal protection must be

used to prevent splashing of material on the

skin or in the eyes.

Always disconnect power source

(electricity, air or hydraulic) from the pump

when it is not being used.

This equipment generates very high

grease pressure. Extreme caution should be

used when operating this equipment as

material leaks from loose or ruptured

components can inject fluid through the skin

and into the body. If any fluid appears to

penetrate the skin, seek attention from a

doctor immediately.

Do not treat injury as a simple cut. Tell

attending doctor exactly what type of fluid

was injected.

Any other use not in accordance with

instructions will result in loss of claim for

warranty or liability.

• Do not misuse, over-pressurize, modify

parts, use incompatible chemicals, fluids,

or use worn and/or damaged parts.

• Do not exceed the stated maximum

working pressure of the pump or of the

lowest rated component in your system.

• Always read and follow the fluid

manufacturer’s recommendations

regarding fluid compatibility, and the use

of protective clothing and equipment.

• Failure to comply may result in personal

injury and/or damage to equipment.

Indicates a hazardous situation which,

if not avoided, could result in minor or

moderate injury.

CAUT ION


if not avoided will result in death or

serious injury.

WARN ING


if not avoided, will result in death or

serious injury.

DANGER

Safety instruction signs indicate

specific safety-related instructions

or procedures.

SAFET Y INSTRUCT IONS

This is the safety alert symbol. It is used

to alert you to potential physical injury

hazards. Obey all safety messages that

follow this symbol to avoid possible

injury or death.

3

OverviewThis service page details the procedure that

must be followed while installing, operating

and repairing the FlowMaster II rotary

driven hydraulic pump.

All required parts, tools, and equipment

needed to complete the operation of the

FlowMaster II rotary driven hydraulic pump

are defined and listed within this manual.

Review of the parts list and nomenclature

is recommended before starting

disassembly or operation.

Appropriate useAll pump models are exclusively designed

to pump and dispense lubricants using

hydraulic power. The specifications are

shown in table 1 for the pump.

The maximum specification ratings should

not be exceeded.

Any other use not in accordance with

instructions will result in loss of claims for

warranty and liability.

Use of this manual

General description and information

The FlowMaster II rotary driven hydraulic

pump is a fully hydraulically operated

adjustable grease pump.

A 24 V DC solenoid valve is incorporated

as a method to turn the pump on and off.

On this model the pressure gauge is

optional and may or may not be shown in

the graphics in this manual.

Table 1 details the grease output in

proportion to the hydraulic input, which is

affected by temperature.

Grease output is proportional to the

hydraulic input flow. The pump is primarily

designed for centralized lubrication systems

such as the single line parallel. Single line

progressive and two line systems. An inte-

grated pump control manifold is incorp-

orated with the input flow and pressure.

The pump is driven by the rotary motion

of the hydraulic motor. Rotary motion is

converted to reciprocating motion through

an eccentric crank mechanism. The recipro-

cating action causes the pump cylinder to

move up and down. The unit is a positive

displacement double-acting pump, as

grease output occurs during both the up and

down stroke.

During the down stroke, the pump

cylinder is extended into the grease.

Through the combination of shovel action

and vacuum generated in the pump cylinder

chamber, the grease is forced into the pump

cylinder. Simultaneously, grease is

discharged through the outlet of the pump.

The volume of grease during intake is twice

the amount of grease output during one

cycle. During the upstroke, the inlet check

closes, and one half of the grease taken in

during the previous stroke is transferred

through the outlet check and discharged to

the outlet port.

Fig. 1, page 5 is the hydraulic schematic

showing the key sub-assemblies of the

pump. Fig. 3, page 7 depicts the actual

location of those items.

InspectionIf over pressurizing of the equipment is

believed to have occurred, contact the

factory authorized warranty and service

center nearest you for inspection of the

pump.

Specialized equipment and knowledge is

required for repair of this pump.

Annual inspection by the factory

authorized warranty and service center

nearest you is recommended.

Damaged pumpsDo not use any pump that appears to be

damaged, badly worn or operates

abnormally.

Remove the pump from service and

contact the factory authorized warranty and

service center nearest you for repairs. A

listing of authorized warranty and service

centers is available upon request.

Table 1

Pump specifications

Hydraulic inlet flow 1.5 U.S. gpm (5,7 liters/min.)Operating temperature –40 to 150 °F (–40 to 65 °C)Operating working hydraulic pressure 360 psi (25 bar)Solenoid voltage, for the on/off solenoid 24 V DCHydraulic inlet port, in SAE 4Tank return port, in SAE 6Supply inlet hydraulic pressure Maximum 3,000 psi (206 bar)Pump outlets, in 1/4 in. NPTFMaximum hydraulic fluid temperature 250 °F (121 °C)Pump ratio with manifold 10:1

4

Fig. 1

T

P1

10

6

5

7

98

2

3

4

Call out Nomenclature

1 Hydraulic fluid inlet port SAE 4 ORB2 Hydraulic fluid return to tank SAE 6 ORB3 Hydraulic motor

4 Lube outlets 0.25 in. NPTF5 Flow control valve6 Pressure gauge

7 Hydraulic fluid to vent valve8 Orifice 0.013 in. (0.33 mm) diameter9 Pressure reducing valve

10 Solenoid valve

0

2 (32)

4 (65)

6 (98)

8 (131)

10 (163)

12 (196)

14 (229)

-20 (-26) -10 (-23) 0 20 (-6) 40 (-4) 80 (26)

Grease output vs. temperature at 1.5 U.S. gpm (5,7 liters/min.) hydraulic flow rate

Grease output, [in. 3/min.(cm3/min.)]

Temperature [°F (°C)]

Diagram 1

5

Fig. 2

Pump dimensions

/4 NPTFLube outlets

1.25 in.

C

B

A

9.55 in.8.75 in.

11.71 in.

2.25 in.

2.25 in.

(222 mm)

(32 mm)

(243 mm)

(297 mm)

(57 mm)

(57 mm)

(99 mm)

3.90 in

(4x) 0.28 in. (7 mm) holes

(4x) /4-20 threads1

1

Model Dimension A in. (mm) Dimension B in. (mm) Dimension C in. (mm)

85847 27.10 (688) 24.69 (627) 15.76 (400)85769 38.90 (988) 36.49 (927) 27.56 (700)

6

Fig. 3

Notice

If it is necessary to drill mounting

holes into reservoir cover, refer to fig. 2

for hole pattern and dimensions.

!Installing the PumpThe pump was tested in lightweight oil

which was left in to protect the pump from

corrosion. Flush the pump before

connecting it to the system to prevent

contamination of the grease with

residual oil.

The pump has flow and pressure controls

integrated into the manifold (66) which are

not adjustable by the user. A normally closed

on/off solenoid valve (67 and 68) is also

integrated into the manifold and will start or

stop the pump operation. A manual override

is on the pump that will allow starting and

stopping of the pump.

1 Mount the pump securely on the drum

cover so that it cannot move or vibrate

during operation. Refer to fig. 4.

2 Attach hydraulic supply line to the inlet

and return line to the manifold ports.

3 Connect material supply line to the pump

outlet.

4 Plug the unused outlet on the opposite

side of the pump.

5 Install high pressure shut-off valve in the

material supply line. (Required).

6 Connect a 24 V DC power supply to the

solenoid coil (74), using the supplied plug.

Fig. 4


A Hydraulic fluid inlet port SAE 4 ORBB Hydraulic fluid return tank SAE 6 ORB72 Hydraulic motor

70 Pressure reducing valve69 Flow regulator67 Solenoid valve

64 Pressure gauge55 Lube outlets 1/4 NPTF

67

72

55

64

70

A

B

7

Operation

Notice

Do not exceed maximum

operating temperature of the hydraulic

fluid 250 °F (121 °C).

Never allow the pump to run dry of

lubricant. A dry pump quickly speeds up,

creating friction heat, which can damage

the seals. Monitor supply lubricant level

and refill when necessary.

Failure to comply may result in

damage to equipment.

!

Crankcase oil service interval

• Check the oil level after every 750 hours

of machine operation, or monthly.

• Change the oil after every 2,000 hours of

machine operation or every year.

• Use SAE 10W30 motor oil in all units

used in an ambient temperature of

–40 to 150 °F (–40 to 65 °C). For ambient

temperatures of 50 to 70 °F (10 to 21 °C)

use Mobil Aero HFA low temperature oil.

• Oil level should be at indicating dot on

dipstick (middle of crankshaft).

• Use 10W30 motor oil 15 oz. (0,44 l).

1 Shut off the material supply line valve.

2 Turn on the hydraulic pressure.

3 Energize the solenoid on/off valve.

4 Prime the pump by slowly opening the

shut-off lubricant supply line valve.

5 Purge air from the pump.

6 Verify lubricant is flowing evenly from

the pump.

!Notice

Fig. 5 depicts the location of the

operating valves for the pump.

!Notice

All pumps are factory set at

360 psi (25 bar) working inlet

hydraulic pressure, with a flow rate of

1.5 U.S. gallons/min. (5,7 liters/min.).

Settings are not adjustable.

Do not exceed 400 psi (27 bar) working

hydraulic pressure. Use high pressure

components to reduce risk of serious

injury including fluid injection and

splashing in the eyes or on the skin.

All accessories connected to the pump

outlet must have at least 5,000 psi

(344 bar) minimum hydraulic operating

pressure. All accessories connected to

the pump inlet must have at least

3,000 psi (206 bar) minimum

working pressure.

Failure to comply may result in

personal injury.

WARN ING

74

3767

72

3135

33

36

69

70

A

B

Fig. 5


A Hydraulic fluid inlet port SAE 4 ORBB Hydraulic fluid return to tank SAE 6 ORB55 Lube outlet 1/4 NPTF

64 Pressure gauge69 Flow regulator67 Solenoid valve with manual override

70 Pressure reducing valve72 Hydraulic motor

8

DisassemblyPump

1 Place pump into a vise.

2 Remove dipstick (31). Refer to fig. 6.

3 Drain crankcase oil.

4 Remove housing cover screws (33).

5 Remove housing cover (35) and

gasket (36).

6 Remove the hydraulic motor mounting

screws (74) and lock washers (73).

7 Remove hydraulic motor (72).

8 Remove manifold assembly mounting

screws (65).

9 Remove manifold assembly (66).

10 Remove pressure reducing valve (70).

11 Remove flow regulator (69).

12 Remove solenoid valve cartridge (67).

13 Remove the outlet pin nuts (55) from

both sides of the pump housing (37).

Refer to fig. 7.

14 Using a blunt tool, remove the o-rings

(54), (53) and back up washer (52) from

outlet pin nuts (55).

15 Loosen the screws (44) holding the

shaft cover (46) on the pump

housing (37).

16 Remove the retaining ring (48) from the

pump shaft (40).

17 Remove the pump shaft (40) by pushing

the pump shaft on the retaining ring

(48) side.

18 Remove the retaining ring (63) from the

housing tube (60). Refer to fig. 7.

19 Remove the shovel plug (62) from the

housing tube (60).

20 Remove the spiral retaining ring (61).

21 Loosen and remove the tube

housing (60). Refer to fig. 7.

22 Remove the bronze bearing (56) from

the tube housing (60). Refer to fig. 8.

23 Using a flat, blunt tool, remove the

o-ring (57) from the tube housing (60).

24 Remove the back up washer (58) from

the tube housing (60).

33 34 35

7

44

45

46

48

60

61

62

63

40

52

53

5455

Fig. 7

56

57

58

59

60

61

62

63

Fig. 8

25 Using a flat, blunt tool, remove the

o-ring (59) from the tube housing (60).

26 Using a rubber mallet and piece of brass

or other suitable piece of soft metal,

tap on the crank rod (7) inside the

housing (37).

27 Pull the eccentric (5) and crank rod (7)

out of the top of the pump housing (37).

End of procedure.

!Notice

Slight force may be necessary to

remove the eccentric (5) and crank rod

(7) from the housing (37). Tap on the

crank rod (7) until the eccentric (5) is

above the pump housing (37) and can

be pulled from the pump housing (37).

Fig. 6

74

3767

72

3135

33

36696670

9

Crankrod and eccentric1 Remove pivot screws (11) from the

crankrod (7). Refer to fig. 9. 3433 35

744

45

46

48

60

61

62

63

40

52

53

5455

Fig. 9

2 Using a 5/16 in.–24 bolt, press out wrist

pin bushing (12).

3 Loosen and remove the wrist pin

anchor (13) from reciprocating tube

(25). Refer to fig. 10.

4 Pull the cup seal (16) out of the wrist

pin anchor (13).

5 Remove the steel backup ring (17).

6 Place the plunger link rod (20) in a vise.

7 Using an open ended wrench, loosen

the plunger link rod (20) and remove

from the outlet pin (8).

8 Remove the plunger link rod (20).

9 Remove the retainer clip (19) from the

plunger link rod (20).

10 Using a blunt tool, remove the o-ring

(18) from the plunger link rod (20).

11 Remove the back up washer (15) from

the plunger link rod (20).

12 Remove the o-ring (14) from the

plunger tube (52).

13 With the crank rod in a vise and using

the special tool (T1) provided in tool kit,

276275 remove the plunger link rod


14 Place the end of the plunger link rod

(20) into the hole of the tool (T1).

15 Align the outlet hole of the plunger link

rod (20) with the hole in the special tool

(T1). Refer to fig. 11.

16 Insert the pin included in the tool kit

(276275) through the tool and into the

plunger link rod (20) outlet hole.

17 Turn the tool counter clockwise to loos-

en the lower bushing and plunger (24)

from the plunger link rod (20).

18 Remove the plunger (24).

19 Remove the check rod from (22) the

lower bushing and plunger (24).

20 Remove the ball (23) from the lower

bushing and plunger (24).

21 Remove the spring (21) from the

link rod (20).

End of procedure.

10

17

18

13

14

15

16

19

20

21

30

29

28

26

27

2425

23

228

9

Fig. 10

!Notice

Wrist pin bushings (12) often stick

in wrist pin anchor (13). It may be

necessary to use a 5/16–24 bolt from kit

(276275) to remove the wrist pin

bushings (12).

10

Reciprocating tube1 Loosen the check seat housing (30)

with 3/8 in. (9 mm) hex head wrench.

Refer to fig. 11.

2 Remove the check seat housing (30)

from the reciprocating tube (25).

3 Remove the ball cage (28), check ball

(29) and o-ring seal (27) from the check

seat housing (30).

4 Remove the lower bushing (24) from the

reciprocating tube (25).

5 Remove the lower cup seal (26) from the


Fig. 12

1

7

2

4

3

3

4

2

5

1

6

Crankrod 1 Using a hex head wrench, loosen and

remove the two flat head screws (1) from

the eccentric (5). Refer to fig. 12.

2 Remove the counterbalance weights (2).

3 Remove the outer (3) and inner (4)

retaining ring from both sides of the

crank rod (7).

4 Place the crankrod (7) on the supplied

2 1/2 in. (62 mm) diameter steel pipe.

5 Drive the crank eccentric (5) out of the

ball bearing (6).

6 Drive the ball bearing (6) out of the

crank rod (7).

End of procedure.

Fig. 11

T1

11

AssemblyCrankrod and eccentric assembly

1 Place the crank rod (7) on the supplied

2 1/2 in. (62 mm) diameter steel pipe.

2 Refer to fig. 13 and install the ball

bearing assembly (6) into the

crank rod (7).

3 Place the eccentric (5) in the

ball bearing (6).

4 Place one end of the inner retaining ring

(4) on top of the eccentric (5).

5 Squeeze the other end of the retaining

ring (4) toward the center and slide

retaining ring (4) into place.

6 Place one end of the outer retaining ring

(3) on top of the inner retaining ring (4).

7 Squeeze the other end of the retaining

ring (4) toward the center and slide

retaining ring (4) into place.

8 Align the holes of the counter-balance

weights (2) with the threaded holes of

the eccentric (5) and place on

the eccentric (5).

9 Insert the flat head screws (1) into the

counter-balance weight (2) and torque

the flat head screws (1) to a torque of

100–110 in.lbf. (11,3–12,4 Nm).

Pump1 Install the ball (23) into the lower

bushing and plunger (24). Refer to

fig. 14.

2 Insert the check rod (22) into the pump

plunger (23).

3 Place the spring (21) onto the check

rod (22).

4 Thread the plunger link rod (20) into the

pump plunger (24).

5 Insert the lower bushing pump plunger

(24) into the suppled tool.

6 Align the hole in the lower bushing

pump plunger (24) with the hole in the

tool (T1).

7 Insert the supplied pin into the hole of

the tool (T1) and into the lower bushing

pump plunger (24).

8 Torque the lower bushing pump plunger

(24) to a torque of 110 to 125 in.lbf.

(12,4 to 14,1 Nm).

9 Install the steel back up ring (17) onto

the threads of upper bushing and

plunger end (10).

10 Slide the o-ring (18) onto the upper

bushing and plunger end (10).

11 Install the retaining clip (19) on the

upper bushing and plunger end (10).

12 Install the o-ring (9) on the upper

bushing and plunger end (10).

13 Place the outlet pin (8) into a vise.

14 Apply Loctite 242 to the threads of the

upper bushing and plunger end (10).

Fig. 15

T1

15 Thread the upper bushing and plunger

end (10) into the outlet pin (8).

16 Torque to 110 to 125 in.lbf.

(12,4 to 14,1 Nm).

17 Install the back-up washer (15) in the

wrist pin anchor (13).

18 Place a new cup seal (16) inside the

wrist pin anchor (13).

19 Clean the threads of the wrist pin

anchor (13).

20 Install the o-ring (14) on the wrist pin

anchor (13). Refer to fig 14.

21 Insert the upper bushing and plunger

end (10) into the wrist pin anchor (13)

and tighten.

22 Place the wrist pin anchor (13) in a vise.

23 Tighten the wrist pin anchor (13) to a

torque of 20 to 25 ft.lbf. (27 to 34 Nm).

Fig. 13

1

7

2

4

3

3

4

2

5

1

6

10

17

18

13

14

15

16

19

20

21

30

29

28

26

27

2425

23

228

9

Fig. 14

12

24 With the wrist pin anchor (13) still in the

vise, align the crankrod/eccentric as-

sembly (7) holes with the wrist pin an-

chor (13) holes. Refer to fig. 16.

25 Install the wrist pin bushings (12)

through the crank rod (7) and into the

wrist pin anchor (13). Refer to fig. 16.

26 Apply Loctite 242 to the threads of the

wrist pin bushing screws (11).

27 Insert and thread the wrist pin bushing

screws (11) into the crankrod (7).

28 Torque bushing screws (7) to a torque

of 110 to 125 in.lbf. (12,4 to 14,1 Nm).

29 Install the cup seal (26) with the slotted

side toward the center of the


30 Place a new o-ring (27) on the lower

bushing and plunger (24).

31 Slide the lower bushing and plunger

(24) into the reciprocating tube (25)

with the o-ring (27) near the bottom of

the reciprocating tube (25). Refer to

fig. 17.

32 Install the steel check cage (28) into the


33 Install the ball (29) into the steel check

cage (28).

!Notice

For ease of installation of the low-

er cup, use a small piece of tubing to

slide the lower cup into the reciprocating

tube and over the pump plunger.

7

12

11

Fig. 16

56

57

58

59

60

Fig. 18

34 Install o-ring (27) onto check seat

housing (30).

35 Apply Loctite 242 or equivalent to the

threads of the check seat housing (30).

36 Thread the check seat housing (30) into

the reciprocating tube (25) and tighten

using a 3/8 in. (9 mm) hex key.

37 Torque to 20 to 25 ft.lbf. (27 to 34 Nm).

38 Remove the crank rod (7) from the vise.

10

17

18

13

14

15

16

19

20

21

30

29

28

26

27

2425

23

228

9

Fig. 17

39 Refer to fig. 18 and insert the o-ring

(59) into the housing tube (60).

40 Place the back up washer (58) into the

housing tube (60).

41 Insert the o-ring (57) into the housing

tube (60).

42 Insert the bronze bearing (56) into the

housing tube (60).

43 Position the crankrod assembly (7) over

the top of the pump housing (37) and

lower into the pump housing (37).

13

44 Align the crank rod (7) with the shaft

(40) mounting hole. Refer to fig. 19 and

fig. 20.

45 While aligning the key (39) on the shaft

(40) with the eccentric key way (5), slide

the shaft (40) into the eccentric (5). Re-

fer to fig. 20.

46 Install the retaining ring (48) on the

shaft. (40).

Fig. 20

31

33

34

35

36

37

Fig. 2151 Install the screws (33) with o-rings (34)

into the pump cover (35).

52 Torque the screws (33) to a torque of

10 to 15 in.lbf. (1,1 to 1,6 Nm).Insert

and thread the housing tube (60) into

the pump housing (37). Refer to fig. 22,

page 15.

53 Install the hydraulic motor (72) on the

pump housing (37).

54 Thread the hydraulic motor mounting

screws (74) with lock washers (73) into

the pump housing (37).

55 Torque the mounting screws (74) to a

torque of 50 to 55 ft.lbf.

(67,8 to 74,5 Nm). Refer to fig. 22,

page 15.

56 Install the o-rings (71) in the motor


57 Place the manifold (66) on the hydraulic

motor (72).

58 Thread the four manifold mounting

screws (65) into the manifold (66).

59 Torque the screws to 20 to 25 ft.lbf.

(27,1 to 33,9 Nm).

60 Install the manual override solenoid

valve (67) into the manifold (66).

61 Torque the solenoid valve (67) to a


62 Install the pressure reducing valve (70)

in the manifold (66).

63 Torque the pressure reducing valve (70)

to a torque of 35 to 40 ft. lbf.

(47 to 54 Nm).

64 Install the flow regulator (69) into the

manifold (66).

65 Torque the flow regulator (69) to a


66 Refer to fig. 22, page 15 and torque

the housing tube (60) to a torque of 20

to 25 ft.lbf. (27,1 to 33,9 Nm).

67 Refer to fig. 22 and insert the retaining

ring (61) into the second groove of

the housing tube (60).

44

45

46

48

40

39

7

37

Fig. 19

!Notice

Failure to align the key on the

shaft and the key way in the eccentric

will result in damage to equipment.

47 Install the shaft cover (46) on the pump


48 Insert and thread screws (44) with lock

washers (45) into shaft cover (46) and

pump housing (37).

49 Install new cover gasket (36) on pump

housing (37). Refer to fig. 21.

50 Install the pump cover (35).

68 Install the shovel plug (62) into the

housing tube (60).

69 Install the spiral retaining ring (63).

70 Install the o-ring (54) in the outlet pin

mounting hole groove of the pump

housing (37), as shown in

fig. 22, page 15.

71 Install the back up washer(52) inside

the outlet pin nut (55).

72 Install the o-ring (53) inside the outlet

pin nut (55).

73 Line up the outlet pin and thread the

outlet pin nut (55) into the pump

housing (37).

!Notice

Refer to page 8 crankcase oil

service for oil recommendations.

74 Torque to 30 to 35 ft.lbf. (40 to 47 Nm).

75 Fill the crankcase with oil up to indicator

dot on dipstick (31).

76 Install the crank case oil dip stick (31)

and torque to 10 to 15 in.lbf.

(1,1 to 1,7 Nm). Refer to fig. 22,

page 15.

End of procedure.

5

14

Troubleshooting

Condition Possible cause Corrective action

Pump does not run No pressure on gauge (64)

Open shut off valve• Closed supply line shut off valve• No power to solenoid valve (68) Correct electrical fault• Faulty solenoid (68) Replace solenoid (68)

• Insufficient hydraulic fluid supply Check hydraulic supply for proper pressure and flow

Pressure is shown on gauge (64)• Closed fluid outlet line Check outlet line and clear obstructions• Pump is stalled due to grease back pressure• Pump is seized or damaged

Check vent valve in systemDismantle the pump and repairDefective or seized componentSee disassembly and assembly procedure

Pump speeds up or runs erratically Low level of grease or reservoir is empty Refill reservoirFollower plate is stuck and separated from grease Check follower plate and container for damagePump piston or checks are worn Disassemble the pump and repair

Pump runs, but output is low Insufficient hydraulic fluid supply Check hydraulic supply and adjust flow using valve (69)

Inlet pressure low Increase pressure using valve (70)Faulty inlet (29, 30), faulty discharge check(23, 24) or damaged o-ring (27)

Replace faulty components

Weepage from housing cover (35) Cup seal (16) or o-ring (14) wore out Check seals and replace if necessary

Pump becomes noisy Crankcase needs oil Check dipstick (31) and fill with oil as required

Pump does not build pressure Worn wrist pin bushing (12)Foreign material holding lower check open

Check the bushings and replace if necessaryDismantle and clear checkConsider adding grease filter to system

15

Parts and tools

Tool list

7/16 in. open end wrench1 1/2 in. open end wrench3/4 in. open end wrench

12 in. adjustable wrench1/8 in. hex head wrench5/32 in. hex head wrench

1/4 in. hex head wrench5/16 in. hex head wrench3/8 in. hex head wrench

1/4 in. drive socket1/4 in. socket5/16 in. socket

Pick to remove seals and spiral retaining ringsSmall snap ring pliersSpecial tool kit 276275

Phillips screwdriver1/2 in. hex head wrenchHammer

Torque wrench ft.lbf. and in.lbf. (Nm)Hex head socket adapters (required to torque hex head screws)Loctite 242 medium strength thread lock or equivalent

16

Parts list

Item no. Description Part no. Quantity Item no. Description Part no. Quantity

1 Flat head screw (1/4–28 x 1 3/4) 270635 2 39 Woodruff key 272560 12 Counter weight 272197 2 40 Pump shaft 277397 13 Retaining ring 270609 2 41 Retaining ring 272561 1

4 Retaining ring 270608 2 42 Ball bearing 272556 15 Crank eccentric 270666 1 43 Shaft seal 2725542) 16 Ball bearing 270607 1 44 Screws 272557 4

7 Crank rod 270665 1 45 Lock washer 66051 48 Outlet pin 270670 1 46 Bearing cover 272549 19 O-ring (nitrile) 342551),2) 1 47 O-ring 2725592) 1

10 Upper bushing and plunger 2750001) 1 48 Retaining ring 272563 111 Pivot screw 275006 2 49 Ball bearing 272555 112 Wrist pin bushing 275005 2 50 Retaining ring 272562 1

13 Wrist pin anchor 274992 1 51 Drain plug 244752 114 O-ring 2750152) 1 52 Backup washer 2498372) 215 Backup washer 2749981),2) 1 53 O-ring 2498382) 2

16 Cup seal (polyurethane) 2749991),2) 1 54 O-ring 2707192) 217 Steel back-up ring 2749971),2) 1 55 Outlet pin nut 270619 218 O-ring 2727911),2) 1 56 Bronze bearing 270674 1

19 Retainer clip 2749961),2) 1 57 O-ring (polyurethane) 2498392) 120 Plunger link rod See chart 1 58 Backup washer 2706522) 121 Spring 2771682) 1 59 O-ring (nitrile) 344312) 1

22 Check rod 277167 1 60 Housing tube See chart 123 Ball 3/16 660102) 1 61 Retaining ring 277398 124 Lower bushing and plunger 275002 1 62 Shovel plug 270707 1

25 Reciprocating tube See chart 1 63 Retaining ring 270705 126 Cup seal (polyurethane) 2706252) 1 64 Pressure gauge 270768 127 O-ring (nitrile) 2750112) 2 65 Socket hd screw (5/16-18 x 1 1/4) 270680 4

28 Ball cage 272179 1 66 Manifold 270771 129 Ball 3/16 660012) 1 67 Solenoid valve cartridge 275412 130 Check seat 270664 1 68 Din coil (24 V DC) 275592* 1

31 Dipstick with o-ring 275369 1 69 Flow regulator 277818 132 O-ring 2750152) 1 70 Pressure reducing valve 277819 133 Self-threading screw 8 x 1/2 270633 6 71 O-ring (fluorocarbon) 2712362) 2

34 Gasket (screw) 2529862) 6 72 Hydraulic motor with o-rings 277740 135 Housing cover 275009 1 73 Lock washer (3/8) 272566 436 Cover gasket (nitrile) 2706302) 1 74 Socket hd screw (3/8-16 x 1 1/2) 277405 4

37 Pump housing 278230 1 75 Orifice fitting 270735 138 O-ring 2725672) 1 76 Din plug 242209* 1

Non-common repair partsPart number

Model 85769 Model 85847

20 Plunger link rod 277383 27797525 Reciprocating tube 277734 27797960 Housing tube 277738 277981

1) Included in 275186 repair kit2) Included in 277723 repair kit* Indicates change.

17

Fig. IPB 1

1

10

98

11

13141617

1819

20

21

22

23

25

26

2829

30

27

24

15

3

5

7

3

2

4

6

4

1

2

12

18

61

62

63

Fig. IPB 2

19

Fig. IPB 3

67

68

69

75

66

71

72

74

73

70

64

65

76*

*

* Indicates change.

20

Lincoln industrial standard warranty

Standard limited warranty

Lincoln warrants the equipment

manufactured and supplied by Lincoln to be

free from defects in material and

workmanship for a period of one (1) year

following the date of purchase, excluding

there from any special, extended, or limited

warranty published by Lincoln. If equipment

is determined to be defective during this

warranty period, it will be repaired or

replaced, within Lincoln’s sole discretion,

without charge.

This warranty is conditioned upon the

determination of a Lincoln authorized

representative that the equipment is

defective. To obtain repair or replacement,

you must ship the equipment,

transportation charges prepaid, with proof

of purchase to a Lincoln Authorized

Warranty and Service Center within the

warranty period.

This warranty is extended to the original

retail purchaser only. This warranty does not

apply to equipment damaged from accident,

overload, abuse, misuse, negligence, faulty

installation or abrasive or corrosive material,

equipment that has been altered, or

equipment repaired by anyone not

authorized by Lincoln. This warranty applies

only to equipment installed, operated and

maintained in strict accordance with the

written specifications and recommendations

provided by Lincoln or its authorized field

personnel.

This warranty is exclusive and is in lieu

of any other warranties, express or

implied, including, but not limited to, the

warranty of merchantability or warranty

of fitness for a particular purpose.

Warranty on items sold by Lincoln, but

not manufactured by Lincoln are subject

to the warranty consideration, if any, of

their manufacturer (such as hoses,

hydraulic and electric motors, electrical

controllers, etc.) Assistance in making

such warranty claims can be offered as

required.

In no event shall Lincoln be liable for

incidental or consequential damages.

Lincoln’s liability for any claim for loss or

damages arising out of the sale, resale or

use of any Lincoln equipment shall in no

event exceed the purchase price. Some

jurisdictions do not allow the exclusion or

limitation of incidental or consequential

damages, therefore the above limitation or

exclusion may not apply to you.

Special limited warranties

Special limited 2 year warranty

SL-V series, single injectors-85772,

85782,replacement injectors-85771,

85781 and FlowMaster II 85731, 85732,

85733 and 85734

Lincoln warrants the SL-V Injector series

and bare FlowMaster II “pump only” models

to be free from defects in material and

workmanship for two (2) years following the

date of purchase. If an injector model (single

or replacement) or "bare" FlowMaster II

pump is determined to be defective by

Lincoln, in its sole discretion, during this

warranty period, it will be repaired or

replaced, at Lincoln’s discretion,

without charge.

Special limited 5 year warranty

series 20, 25, 40 bare pumps, pmv bare

pumps, heavy duty and 94000 series bare

reels

Lincoln warrants series 20, 25, 40 bare

pumps, PMV bare pumps, heavy duty

(82206), mini bench (81133, 81323), and

all 94000 LFR series (single arm and dual

arm) bare reels to be free from defects in

material and workmanship for five (5) years

following the date of purchase. If equipment

is determined by Lincoln, in its sole discre-

tion, to be defective during the first year of

the warranty period, it will be repaired or

replaced at Lincoln’s discretion, without

charge. In years two (2) and three (3), the

warranty on this equipment is limited to

repair with Lincoln paying parts and labor

only. In years four (4) and five (5), the war-

ranty on this equipment is limited to repair

with Lincoln paying for parts only.

Lincoln Industrial contact information

To find Lincoln Industrial’s nearest service

center in the United States, call customer

service at 314-679-4200. For international

callers dial 01-314-679-4200. You may

also use our website lincolnindustrial.com.

Paul G. Conley, Chief Engineer

December 16th, 2003

Declaration of conformity according to

machinery Directive 89/392/EEC

This is to declare that the design of the

FlowMaster II rotary driven hydraulic pump

in the version supplied by Lincoln Industrial,

One Lincoln Way, St. Louis, MO.

63120, U.S.A., complies with provisions

of Directive 89/392/EEC.

Applied harmonized standards in particular:

EN 292-1 Safety of machinery part 1 Basic

terminology, methodology

EN 292-2 Safety of machinery part 2

technical principles and specifications

EN 982 Safety of machinery, safety

requirements for fluid power systems and

their components, hydraulics,

EN 1050 Safety of machinery, principles for

risk assessment

21

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22

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23

® SKF is a registered trademark of the SKF Group.

® Lincoln is a registered trademark of Lincoln Industrial Corp.

™ FlowMaster II is a trademark of Lincoln Industrial Corp.

Mobil is a trademark of Exxon Mobil Corp.

Loctite is a registered trademark of Henkel Corp.

© SKF Group 2014The contents of this publication are the copyright of the publisher and may not be reproduced (even extracts) unless prior written permis-sion is granted. Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or damage whether direct, indirect or consequential arising out of the use of the information contained herein.

SKF PUB LS/I4 14406/R1 · EN · April 2014 · Form 404534C

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Lubrication systems

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The Power of Knowledge EngineeringCombining products, people, and application- specific knowledge, SKF delivers innovative solutions to equipment manufacturers and pro-duction facilities in every major industry world-wide. Having expert ise in multiple competence areas supports SKF Life Cycle Management, a proven approach to improv ing equipment reliabil-ity, optimizing operational and energy efficiency and reducing total cost of ownership.

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